Simulated zero &#34;g&#34; mattress and cover

ABSTRACT

A mattress is provided having three layers of differing properties stacked on top of each other which together have the effect of letting the user sleep in a simulated Zero G position without the aid of an articulating base. Two layers are contoured within the mattress let specific areas of the user&#39;s body sink further into the mattress than others. A cover with removable inserts is also provided for the mattress.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional ApplicationSer. No. 62/262,579, filed Dec. 3, 2015 and U.S. Provisional ApplicationSer. No. 62/410,584, filed Oct. 20, 2016, both of which are incorporatedby reference herein in their entirety.

FIELD OF THE INVENTION

The present invention provides a mattress capable of letting a usersleep in a simulated zero G position.

BACKGROUND

In recent years, many new mattress types have come to market to addressvarious deficiencies in the industry. For example, memory foammattresses have become very popular. However, these mattresses can oftenbe uncomfortable because the memory foam is not very breathable and cancreate hot spots. Further, memory foam mattresses do not provide anycapability for a user to adjust the softness or firmness of themattress, leading to further user discomfort. The mattress of thepresent invention has been designed to address these and other variousdeficiencies.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a view a side cutaway view of a first view of themattress.

FIG. 2 depicts a perspective view of the mattress without a cover.

FIG. 3 depicts a user on their back laying on the mattress.

FIG. 4 depicts a user on their side laying on the mattress.

FIG. 5 depicts a view of the mattress with a cover.

FIG. 6 depicts a view of the mattress with the cover partially removed.

FIG. 7 depicts a view of the mattress with inserts added.

FIG. 8 depicts a top view of the mattress with two inserts attached.

FIG. 9 depicts a cutaway view of the inserts showing the innerconstruction.

FIG. 10 depicts a full cutaway view of the mattress.

FIGS. 11-13 show a view of the mattress being packaged for transportwith the inserts attached.

SUMMARY

Disclosed herein is a mattress comprised of different layers of materialstacked on top of each other which together have the effect of lettingthe user sleep in a “simulated Zero G” position without the aid of anarticulating base. Contoured layers within the mattress let specificareas of the user's body sink further into the mattress than otherswhich create the Zero G effect when sleeping on the back (FIG. 3), andcontour to the user's body when sleeping on the side (FIG. 4).Specifically, when sleeping on the back, the user's head, upper back andfeet are supported at mattress level, while the torso and hips sink intothe mattress on an even slope. This position is more natural to thehuman body than laying on flat surface with a consistent amount of give& support throughout. Additionally, there is a top layer of materialspecifically designed to retain minimum heat and to dissipate body heatover time, keeping the user cooler while sleeping and to retain thefeeling of “bounce” or “springiness” in the mattress.

DETAILED DESCRIPTION

FIG. 1 shows a side view of mattress 100 with internal layers A-Cvisible. Layer A is a breathable, springy and bouncy structural meshlayer (polymer material or other materials) between one inch and threeinches thick which does not retain heat and serves to add spring andcomfort for the user. For example, Layer A may be a material such asAirstring offered by Spec Tex® or any other similar material. Layer B isformed from a visco-elastic polyurethane foam (memory foam) which has ahorizontal top surface and has a contoured bottom surface so that it isnot a uniform thickness. The purposes of the “zones” formed by thevarious contours of the bottom surface of layer B will be explainedlater. In a preferred embodiment, the visco-elastic polyurethane foam ofLayer B has a density in the range of 3-8 lb/ft̂3, preferably 4 lb/ft̂3.

Layer C is a High Density polyurethane foam (HD foam) which has ahorizontal bottom surface and is cut on a contour on its top surface sothat it perfectly matches and fits together with the bottom contour oflayer B. Preferably, the high density polyurethane foam has a densityrange of 1-3 lb/ft̂3, but preferably 2.8 lb/ft̂3. When fully assembled,the mattress 100 is flat on both top and bottom, appearing similar inshape and size to a traditional mattress.

Preferably, layers B-C are permanently bonded to each other while layerA is removable as will be described later. However, it should beapparent that layers A-C can all be permanently bonded or attached toeach other using known methods in the art.

The mattress is divided laterally by five “zones” which are defined bythe contour line (FIG. 1) (or contact area between the bottom of layer Band the top of layer C). Zone 1 is a fully horizontal section startingat the head of the bed and extending from one inch in length to 18inches along a length of mattress 100. Zone 2 is a transition areabetween Zone 1 and Zone 3, and extends from the end of Zone 1 from 1inch to 20 inches along a length of mattress 100. As previouslyexplained, the top surface of layer 2 is flat while the bottom surfaceof layer 2 extends downward toward a bottom of mattress 100 at an anglewhich can vary from 5 degrees to 85 degrees from horizontal. Thetransition of layer B in zone 2 from flat to sloped can either be asharp transition, as shown in FIG. 1, or a smooth transition with aconvex surface into zone 1 and a concave surface into zone 3.

Zone 3 is a horizontal section symmetrical about the centerline of thebed connecting zone 2 and zone 4 in which layers A-C have a constantthickness. In zone 3, layer B is the thickest layer. Zone 4 is a mirrorimage of zone 2 and zone 5 is a mirror image of zone 1 about thecenterline of the mattress 100. Because mattress 100 is symmetrical, auser can lie lengthwise in either direction. Table 1 below summarizesthe thicknesses of the various layers in the various zones:

TABLE 1 Zones 1 & 5 Zones 2 & 4 Zone 3 Layer A 1-4″ 1-4″ 1-4″ Layer B1-4″ Start—1-4″ 2-10″ End—2-10″ Layer C 3-16″ Start—3-16″ 1-10″End—1-10″

Layers B and C work together to create a support system for the bodythat allow for the “simulated Zero G positon.” The HD foam of layer Cprovides support which will give less under the user's weight, thusdefining the user's sleeping position. The memory foam of layer Bprovides comfort and “give”, letting the user sink into the mattress100. Areas where the memory foam is thicker in layer B, such as zone 3,provide a deeper sink and a more customized contour for the user's body.Areas with thicker HD foam in layer C, such as zones 1, 2, 4, and 5,provide more support and definition.

Layer A has a number of distinct roles. Its first function is to bebreathable, retain as little heat as possible and dissipate body heatover time, keeping the user cool while sleeping and separating the userfrom the memory foam of layer B which otherwise would retain much of theuser's body heat. Secondly, layer A functions to distribute the weightof the user onto layer B. Memory foam deflects at highly local levelswhich can create a “sunk in” feeling, which prevents the user fromeasily moving/changing-position during sleep and also does not providethe ideal amount of support for all areas of the body. Layer A deflectsin a very broad way, conforming to the body contour while distributingthe weight of the user evenly over the memory foam's surface. In thisway the memory foam will still offer the benefit of its “give” orvertical deflection, but layer A will prevent the “sunk in” feeling.Layer A also offers a desirable level of spring or bounce, common to aninnerspring mattress, which foam alone cannot provide.

Zone Roles for Back Sleeping (FIG. 3)

As shown in FIG. 3, when a user lays on their back on mattress 100, zone1 supports the user's head, keeping it raised above the mattress. Zone 2supports the user's shoulders and upper back and defines the angle fromhorizontal that the user will sleep at. Zone 3 has a deeper area ofmemory foam in layer B that lets the user's hips and lower back sinkinto the mattress. Zones 4 and 5 support the user's legs but the contourunderneath does not affect leg resting position as the legs are notheavy enough to sink into the mattress. Zone's 4 and 5 exist in order tokeep the mattress 100 symmetrical, in this way the user can not set upthe mattress in an incorrect orientation.

If the user sets up the mattress 100 in reverse (head resting on Zone5), zones 5 and 4 will function identically to zones 1 and 2respectively. Together, these zones create the “simulated Zero G”position where the back/spine is in alignment in a downward slope (headrests higher than the hips) and the legs are elevated in a semi bentposition.

Zone Roles for Side Sleeping (FIG. 4)

As shown in FIG. 4, when a user lays on their side on mattress 100, zone1 supports the user's head, keeping it raised above the mattress. Zone 2offers a thicker section of memory foam to allow the user's shoulders tosink in further by following the neck, shoulder and arm and bodyprofile. Zone 3 offers the thickest section of memory foam to allow theheaviest areas of the body, the hips and torso, to sink in. Sections 4and 5 offer less memory foam which still provide adequate support forthe legs. This setup for side sleeping keeps the head supported andkeeps the spine relaxed and naturally straight and in a parallelalignment with the floor.

Cover Construction (FIG. 5)

In some embodiments, mattress 100 is further provided with a cover 500which comprises top cover 502, inner cover, 504, and lower portion 506.Top cover 502 is joined to lower portion 506 through exterior zipper 508which can be used to completely separate top cover 502 from lowerportion 506. Piping 510 can be used to conceal the path of zipper 508 sothe user never feels the metal or plastic zipper around the edge of themattress cover 500 (FIG. 5, FIG. 6). The zipper 508 and piping 510follow the same path around the perimeter of the mattress 100. On theshort ends of the mattress 100, the zipper 508 and piping 510 are on astraight line near the top of mattress 100. On the long sides ofmattress 100, the zipper 508 and piping 510 dip downward in a consistentconvex arc ranging anywhere from 3″ to 10″ deep (FIG. 5). The other sideof mattress 100 not shown in FIG. 5 is a mirror image of that shown inFIGS. 5-6.

The cover 500 is constructed so that the user can unzip the top layer502 as shown in FIG. 6 (FIG. 6). This is primarily so the user canaccess inner cover 504 located beneath top layer 502 (FIG. 7). The toplayer 502 can be removed for spot washing, washing in a washing machine,dry cleaning, or replacement.

Top layer 502 generally comprises two distinct materials. The firstmaterial, ticking 512, is a soft fabric which is quilted to an internalspacer fabric 1002 (FIG. 10) in consistent width increments (FIG. 5). Asan example, ticking 512 may be 500 gram 100% polyester. A fire retardantfabric, such as Palidn FR fiber, may also be used.

The internal spacer fabric enhances the breathability of the entiremattress and adds a plush-like topper to mattress 100. Spacer fabricsare generally made up of two breathable pieces of fabric that have fineplastic threads oriented vertically between the two fabrics to create adefined space between the two pieces of fabric. The thickness of thespacer fabric located internal to ticking 512 can vary from 2 mm to 75mm in thickness.

Inner Cover Construction (FIG. 7)

In some embodiments, inner layer A of the mattress 100 shown in FIGS.1-4 may be inside one or more removable inserts 700 as depicted in FIG.7. For full, queen, king and California king mattresses, layer A is madeup of 2 inserts 700. However, in some embodiments, layer A may be madeup on a single insert 700 that is the full length and width of mattress100. Each insert 700 is preferably zippered to inner cover 504 usinginsert zippers 706. However, other connection means, such as hook andloop fasteners, may also be used to attach inserts 700 to inner cover504.

Inner cover 504 and lower portion 506 fully encase layers B and C sothat the user is never exposed to those layers (FIG. 7). In someembodiment, inner cover 504 is formed from a waterproof fabric toprevent any spills from traveling to parts of the mattress that are notwashable. Inner cover 504 extends around the border of the mattress 100and is attached to lower portion 506 along the same convex arc as toplayer 502. Preferably, inner cover 504 is sewn to lower portion 506 soit is not removable for holding the piping 510 and zipper 508 in placeon mattress 100. Inner cover 504 also prevents the user from smellinglayers B and C of mattress 100 off-gassing, a natural property in foam.When the user removes top layer 502 to adjust inserts 700, they only seea finished case. The user is never subjected to raw materials as inother foam mattresses (FIG. 7).

The bottom of lower portion 506 comprises a hidden zipper 1004 (FIG. 10)which is used to attach lower portion 506 and inner cover 504 tomattress 100 during production. The construction of cover 500 allows theuser to remove top layer to adjust the firmness using inserts 700 havingvarying densities while still maintaining the look and feel of afinished product (FIG. 6).

Insert Construction (FIG. 9)

In a preferred embodiment, layer A is contained within inserts 700 whichare removable from mattress 100 as has been described. This allows usersto select different densities of layer A to suit two users' uniquesleeping preferences. This can be due to heat, softness/firmnesspreferences, change in sleeping behavior, medical reasons, pregnancy,etc.

As depicted in FIG. 9, Layer A is encased in fabric 902 using a foldedfabric construction in which fabric 902 underneath layer A and is foldedover the top of layer A. In the preferred embodiment, the fabric 902 islightweight and breathable to optimize the breathability of layer A. Theopen edges of fabric 902 are then sewn shut. In the preferredembodiment, the open edges are sewn shut with bias tape 904. Layer A iscompletely encased in the fabric 902 so the user never sees or touchesthe raw material. As shown in FIG. 8, the folded fabric constructionallows for the two inserts 700 to sit side by side with no gap or creasebetween the two inserts 700 when users are laying on mattress 100.

At each end of insert 700 is a zipper 706 used to attach insert 700 toinner cover. In the preferred embodiment, zippers 706 are used toprevent the inserts from shifting while moving the mattress 100. Othermethods of securing the mattress include Velcro strips, strips offabric, or strips of elastic on the corners of the mattress case whichare pulled over layer A to keep inserts 700 in place. The zippers 706 oneach end are designed so an insert can be zipped to either side of themattress 100 by simply rotating the insert 180 degrees.

Roll Pack Packaging

The mattress 100 is packaged for shipment with inserts 700 attachedusing a roll packing method in which the mattress 100 is firstcompressed and sealed in plastic. As shown in FIG. 11, the compressedmattress 100 is then folded in half along the centerline (FIG. 1) sothat both inserts 700 face outward. Mattress 100 is then rolled up asdepicted in FIGS. 12-13 and sealed with a plastic sheet. In thepreferred embodiment, the mattress 100 is folded in the reverse alongthe center line. This prevents any permanent creasing or folding linesto layer A or the mattress case 500 during shipping.

1. A mattress having a length greater than a width, the mattresscomprising: a first layer formed from a breathable and spring-likematerial; a second layer formed from a visco-elastic polyurethane(memory foam); a third layer formed from a high density polyurethanefoam (HD foam); wherein the mattress is divided into five zones alongthe length of the mattress; wherein a thickness of the third layer in afirst zone and a fifth zone is greater than a thickness of the secondlayer; wherein a thickness of the second layer in a third zone isgreater than a thickness of the third layer; and wherein a thickness ofthe first layer is the same in each of the five zones.
 2. The mattressaccording to claim 1, wherein a density of the second layer is 3-8lb/ft̂3 and a density of the third layer is 1-3 lb/ft̂3.
 3. The mattressaccording to claim 1, wherein a thickness of the second layer in asecond zone increases in thickness from 1-4″ at a beginning of thesecond zone to 2-10″ at an end of the second zone.
 4. The mattressaccording to claim 3, wherein a thickness of the third layer in thesecond zone decreases in thickness from 3-16″ at the beginning of thesecond zone to 1-10″ at the end of the second zone.
 5. The mattressaccording to claim 3, wherein the thickness of the second layer in thesecond zone increases at a constant rate.
 6. The mattress according toclaim 1, wherein the fifth zone is a mirror image of the first zone anda fourth zone is a mirror image of a second zone.
 7. The mattressaccording to claim 1, further comprising a cover for the mattress,wherein the cover comprises: a bottom portion fully surrounding a bottomof the mattress and an outer periphery of the mattress, wherein, alongthe length of the mattress, a top of the bottom portion extends downwardin a consistent convex arc from 3″ to 10″, and wherein, along the widthof the mattress, the top of the bottom portion is parallel to a topsurface of the a mattress.
 8. The mattress according to claim 7, furthercomprising: an inner cover connected to the bottom portion along the topof the bottom portion, wherein the top portion and the bottom portionfully surround the second layer and the third layer.
 9. The mattressaccording to claim 8, further comprising: a top cover, wherein the topcover is releasably connected to the top of the bottom portion, whereinthe first layer is located between the inner cover and the top cover.10. The mattress according to claim 8, wherein the inner cover is formedfrom a waterproof material.
 11. The mattress according to claim 8,wherein a top surface of the inner cover comprises at least two zippers,with a first zipper along a top portion of the top surface and a secondzipper along a bottom portion of the top surface, and wherein arectangular insert containing at least a portion of first layer isattached to the top portion using the first zipper and the secondzipper.
 12. The mattress according to claim 11, wherein the rectangularinsert comprises: a fabric layer folded over an edge of the first layer,wherein the edges of the fabric layer are joined on three sides to fullysurround first layer, and a pair of zippers on opposing ends of thefabric layer for mating with the first zipper and the second zipper onthe top surface of the inner cover.
 13. The mattress according to claim11, further comprising: a third zipper aligned adjacent the firstzipper; a fourth zipper aligned adjacent the second zipper adjacent thefirst zipper; and a second rectangular insert containing a remainder ofthe first layer not contained within the rectangular insert, wherein thesecond rectangular insert is attached to the top portion using the thirdzipper and the fourth zipper.
 14. The mattress according to claim 11,wherein the first rectangular insert and the second rectangular insertsubstantially cover the top surface of the mattress.